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Energy, profit and competitive advantage. Three pillars of Mlekpol's success, made possible by the innovative anaerobic digestion plant in Grajewo, realised by SEEN Technologie
In an era of energy transition and increasing regulatory pressure, the dairy industry is facing profound changes. Optimising operating costs alone is no longer enough - implementing solutions based on the circular economy, energy recovery and carbon footprint reduction is becoming crucial. It is in the areas of waste management and energy consumption that these challenges are most visible and felt today. The installation designed and implemented by SEEN Technologie at SM Mlekpol in Grajewo is proof that they can not only be effectively addressed, but can even be transformed into a sustainable source of market advantage.
SM Mlekpol Dairy Cooperative, as one of the largest dairy producers in Central and Eastern Europe, processes more than 6 million litres of milk per day, which naturally generates streams of organic waste and industrial wastewater. Traditional methods of managing them would mean high costs, a burden on the environment and no added value. Thanks to the anaerobic digestion technology used, this waste is turned into a source of biogas, energy, heat and an organic soil conditioner.
– The biogas plant is an energy production technology on the one hand and a strategic tool to support the transformation of dairying towards sustainability on the other. The Grajew anaerobic digestion installation is another step in the implementation of our long-term energy strategy, which involves systematic investment in renewable energy sources at all Mlekpol plants. For us, this is not only a responsibility towards future generations, but also a way to increase competitiveness and energy independence – says Zbigniew Groszyk, Vice-President of the Management Board of SM Mlekpol.
- Our goal was not only to provide a technologically modern plant, but also one that is economically self-sufficient and in line with the idea of a closed-loop economy. In Grajewo, we are not talking about waste disposal - we are talking about its transformation into a valuable resource – points out Dariusz Jasak, President of the Management Board of SEEN Technologie
Engineering tailored to the realities of the dairy industry
The investment was carried out under the “design and build” formula, which enabled every technological element to be fully adapted to the needs of the facility - from the digester feed system to the energy recovery systems.
At the heart of the plant is a digester with a working volume of 6,800 m³, which receives around 230 m³ of waste substrates every day, including sludge from the wastewater treatment process. The mesophilic process ensures biological stability and a high biogas yield of 380 m³/h. After purification and compression, the biogas produced feeds a cogeneration unit that produces 1.2 MW of electricity and approximately 1.3 MW of heat.
– Our installation is not a ready-made set from a catalogue. Each component was individually selected with a view to the rhythm of the plant's operation, the logistical layout and the specificity of the substrates we were dealing with in Grajewo – emphasises Dariusz Jasak
Energy production and measurable operating profits
The year 2024 was the first full period of operation of the installation. During this time, the system generated 5,728 MWh of electricity, giving an average daily production of around 16 MWh. All of the energy was used for the plant's own needs - powering the digester, sludge dryer and other process infrastructure.
With an average energy purchase price of 700 PLN/MWh, this means avoided expenses of around 4 million PLN. The installation also ensured full self-sufficiency in heat and significant energy independence, which translated into reduced operating costs and increased financial efficiency of the plant.
The high efficiency of the system is also reflected in the management of digestate. In 2024, 715,000 kg of dried sludge was produced, which translates into an average daily production of around 1,960 kg. Thanks to the fermentation and drying processes used, the volume of sludge was reduced by up to six times and the resulting material was given a new use. Once the relevant environmental permits have been obtained, this sludge can be used as an organic soil conditioner - providing a valuable by-product with real utility.
As a result, the plant not only generates significant energy savings, but also transforms the waste into a resource, strengthening the long-term economic and environmental sustainability of the plant.
– This is a change in perspective. The treatment plant, which not long ago was treated as a costly addition to production, today generates real profit and improves the balance sheet of the entire plant. This is the best example of how process engineering can really affect a company's financial performance – adds dr. eng. Bogusław Buczak, Proxy and Director of the Process Engineering Department at SEEN Technologie
Real impact on the environment and ESG strategy
The environmental dimension of the investment is also worth highlighting. The production of energy from biogas, the reduction of emissions associated with the transport and disposal of sludge, as well as the complete elimination of the need for external sludge management, have significantly reduced the carbon footprint of the Grajewo plant.
Mlekpol not only reduces CO₂ emissions, but actively implements the assumptions of the European Green Deal and the ‘Fit for 55’ package. For SEEN Technologie, this project proves that industrial energy transformation is much more than changing the power source - it is a comprehensive approach to the plant as an integrated energy and environmental organism.
– Our approach is to combine engineering with economics and environmental strategy. For Mlekpol, we have created not just an installation, but a new source of value. A value that can be counted - both in megawatts and in zlotys – concludes dr. eng. Bogusław Buczak
A new standard for the dairy industry
The anaerobic digestion plant in Grajewo is not only a response to the needs of a specific plant, but also a reference model for the entire dairy sector. It demonstrates that bold investment decisions, taken with the right technology partner, can lead to sustainable operational, energy and environmental transformation.
Mlekpol - as the industry leader - proves that sustainability is no longer a trend, but a necessity to remain competitive. SEEN Technologie, in turn, confirms its position as an integrator of solutions combining advanced engineering with measurable economic benefits.
